Bushing as received measured .118" between lug and flange. Slide measured .110". Would have resulted in an .008" gap between end of slide and bushing flange. About 4-5 sheets of paper.
I machined a flat in the lug slot. Silver soldered in a piece of heat treated 4142 and remachined the slot to .110".

Thanks. I appreciate it. I'm going to buy some new bushings from EGW for my Kimbers (early ones with MIM barrel bushings) and was going to check this dimension as well. I might run the bushing O.D. 0.001 clearance to the slide and 0.002 to the barrel. Am I close here? This isn't a match gun but would like to do it right W.O. affecting reliability.

To clarify, I'm not a MIM hater, but have seen first hand what a broken bushing does to a Kimber (or any 1911 with a broken bushing like that). To me, it's cheap insurance to avoid a big repair bill.

Thanks in advance. Again, if it's taking food off your table, I understand.

Or, I might just send the slides/barrels to you and have a matched bushing/plunger installed with the happy face engraved in it.